Thermal Imaging System for Variable Data Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current digital printing technologies are limited by speed and unable to efficiently handle high viscosity, high pigment concentration inks, leading to productivity issues and image ghosting in variable data printing jobs, especially with viscoelastic marking materials like waterless offset inks.
Innovation Solution
An imaging system with a tunable energy transfer characteristic, using a mask layer with phase change materials like nanocrystalline vanadium dioxide or chalcogenide materials, selectively heats marking materials to temporarily change their viscosity and adhesion properties, allowing for pattern-wise transfer onto a silicone surface without ghosting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If digital printing technologies use thermal transfer methods, then marking material can be transferred to substrate, but large amount of energy is required and print speed is limited
Solution Approach 1:
The patent applies phase transition of marking material from solid to liquid state through controlled heating to enable transfer to substrate. This resolves the contradiction by using the phase change mechanism that allows transfer at lower energy costs compared to traditional thermal transfer methods that require complete phase change and latent heat delivery.
Solution Approach 2:
The patent changes the physical parameters of marking material (temperature, viscosity, adhesion) through controlled heating to enable transfer. By adjusting these parameters dynamically during the printing process, the system achieves both energy efficiency and high print speed without being constrained by fixed thermal transfer limitations.
2Quantity of substance
If digital printing uses high pigment concentration ink, then marking pile height increases, but gloss uniformity and fold fastness deteriorate
Solution Approach 1:
The patent dynamically changes the temperature parameter of marking material during transfer to control viscosity and adhesion properties. This allows high pigment concentration to be used without creating excessive pile height, as the controlled heating ensures uniform distribution and proper adhesion to substrate, maintaining gloss uniformity and fold fastness.
3Productivity
If lithographic printing uses master plate with hydrophobic imaging regions, then high volume duplication is achieved, but variable data printing is limited
Solution Approach 1:
The patent uses a digital imaging system where the marking material application and heating patterns can be dynamically changed for each print job. This allows the system to maintain high productivity through automated digital control while simultaneously achieving variable data printing capability, as each page can be customized without requiring physical plate changes.
4Loss of energy
If offset printing uses 50/50 ink splitting between donor and imaging plate, then transfer efficiency is balanced, but image ghosting occurs in variable data printing
Solution Approach 1:
The patent controls the temperature and adhesion parameters of marking material to optimize transfer efficiency. By heating the marking material to specific temperature ranges, the system achieves near-complete transfer to substrate while minimizing residual material on the imaging surface, thereby preventing image ghosting in variable data printing applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, high-speed, and high-quality variable data printing with viscoelastic marking materials by ensuring near 100% transfer efficiency to substrates, overcoming the limitations of traditional digital printing technologies.
Implementation Method 1
a mask layer (12) formed of a material having a tunable energy transfer characteristic... selectively heats marking materials to temporarily change their viscosity and adhesion properties
Implementation Method 2
pattern-wise heating of a layer of marking material (31) in a nip (11) between the donor structure (22) and image receiving structure (72)
Implementation Method 3
The adhesion force of the silicone interface is further reduced by the fact the silicone surface forms a 'weak boundary layer' with solvents which diffuse into it
Data Source
AI summary
An imaging system including an image receiving structure including a material layer having a tunable energy transfer characteristic; and an energy source to emit an energy beam at the material having the tunable energy transfer characteristic such that marking material is pattern-wise transferred to the image receiving structure.An imaging system includes an image receiving structure disposed to be in direct contact with marking material; and an energy source to emit a pattern-wise modulated energy beam at a region of the image receiving structure contacting the marking material to pattern-wise transfer marking material to the image receiving structure.